Building construction



R. CARVEL May 3, 1932.

' BUILDING conswnucnon 2 Sheets-Sheet Fi'led Sept.

A A IlIlIIIIIIIIII/III/ uni/1, IIIIIIIIIIIIIIIIIIIIIIII E: 7IEVENTO 4 B m 1% ATTORNEYJ R. CARVEL May 3, 1932.

BUILDING CONSTRUGTION Filed Sept. 11, 1930 .2 Sheets-Sheet 2 i INVENTOR A *Z/ I I ATTORNEY Patented May 3, 1932 UNITED STATES PATENT oFFlca caavaa, on NEW YORK, 1t. Y.

Application filed September 11, mac. Serial No. 481,088.

This invention relates to building construction and has as an object the provision of methods of forming concrete wall sections having the exterior appearance of masonry,

5 but at a cost considerably lower than the cost of masonr walls. v

. Other 0 jects and advantages of the invention will appear hereinafter.

A-preferred embodiment of the invention selected for purposes of illustration is shown in the accompanying drawings,-in which,

Figure 1 is a section on the line 1-1 of Figure 2, showing the arrangement of the stone andthe separating strips.

Figure 2 is a section on the line 2-2 of Fi ure 1.

igure 3 illustrates the manner in which the mating sections of the finished wall fit together.

The invention to be described and claimed in this application relates generally to the disclosed and described in in prior application Serial No. 225,426, filed ctober 11, 1927, in which it is roposed to cast'wall sections of relatively arge size, and then to set up the sections to form a finished wall, instead of building the wall piece by iece as is now common tice. It was a so proposed to provide facin material for the said wall sections whic would give the external appearance of ordinary masonry or brick walls.

According to the present invention, the same general procedure is followed to the extent that the wall sections are castin a suitable form and are then set up to form a, finished wall, but it is proposed to treat the wall section in such manner that adjoining units may be easily assembled in such manner that the appearance of ordinary masonry is obtaine For this purpose, a box or form 1 is provided of any desired length, width and depth and a thin layer of sand 2 or other suitable material for protecting the front of the facing material is placed in the bottom of the said box. Immediatel on top of the layer of sand and'pressed t erein toany'gdesired depth is arranged a layer of stone or other suitable facing material 3, the individual .or units sand 1. As will pracstones or units being placed in close proximity one to another. At intervals sufiicient to provide wall sections of suitable size for convenient handling are placed separating strips 3 of rubber or other suitable flexible material, the said strips being preferably sufiiciently flexible so that they ma conform readily to the shape of the individ iial stones or units as illustrated in Figure 1. After the separating strips are thus placed in position, a layer of concrete is poured into the form on top of the layer 2, thus embeddin the stones of the layer 2 therein, ut leaving the bottom surfaces of. the said stones or units clear, due to their rotection by the layer of 05 e understood, the sand may be washed from the finished units after they have been removed from the form.

After the concrete is poured, it is permitted to set and harden, but after the concrete is set and before it has hardened completely, the separating strips 3 may be withdrawn thus leaving, in effect, a plurality of separate wall sections having mating irregularities in the adjoining faces.

As will be apparent, when it is desired to build-the wall, the wall sections may be removed from the form, transported to the desired position, and the adjoining wall sections may be set up as illustrated in Figure 3, the sections being placed one on to I of the other with. a thin layer of grout etween. When the wall is completedand the grout has dried,it is impossible to detect the linev of separation between the sections, and to all external appearances the wall is a solid wall of masonry. i

It is to be understood that the invention may variously modified and embodied within the scope of the subjoined claims.

I claim as my invention:

1. The method of forming concrete wall sections which comprises laying protecting material in a form of predetermmed size and shape, laying facing material thereon, sepaw rating certain portions of the facing material .alon an irregular line by bind the 9 together except same together except along the line of separation.

2. The method of forming concrete wall sections which comprises laying protecting material in a .form of and shape, laying separating certain portions of the facing material by placing a flexible spacing member therebetween which conforms to the shape of the facing material, and pouring concrete over the facingmaterial to bind the same along the line of separation.

3. The method of forming concrete wall sections which comprises layin protecting material in a form of predetermined size and shape, laying facing material thereon, separating certain portions of the facing material alon an irregular line by placing a spacing mem er therebetween conforming to the shape of said facing material, pouring concrete over the facing material to bind the same together except alon the line of sepapredetermined size ration, removing the spacing material, dis

assembling the sections,

and binding the sections in ship with grout.

and reassembling the same relation- 4. The method of forming concrete wallsections which comprises laying protecting material in a form of predetermined size and shape, laying facing material thereon, separating certain portions of the facing material by placing a flexible spacing member therebetween which conforms to the shape of the facing material, pouring concrete over the facing material to bind the same together except along the line of separation, removing the spacing material, disassembling the sections, andreassembling and binding the sections in the same relationship with grout.

5. The method of forming concrete wall sections which comprises shape, placing a flexible spacing member therebetween which conforms to the shape of the facing material, and pouring concrete over the acing material to bind the same together except along the line of separation.

6. The method of forming concrete wall sections which comprises laying facing mablin binding the sections in terial in a form of predetermined size and shape, placing a flexible spacing member therebetween which conforms to the shape of the facing material, pouring concrete over the facing material to bind the same together exce t along the line of separation, removing t e spacing material, disassemthe sections, and reas'sembling and with grout.

- In testimony whereof, I. have signed my nanie to this specificationthis fifth day of September, 1930.

- RICHARD GARVEL.

facing material thereon,

laying facing material in a form of predetermined size and the same relationship 

